US20080220188A1 - Method and system for printing electrostatically or electrographically generated images to contoured surfaces of ceramic and glass items such as dishware - Google Patents
Method and system for printing electrostatically or electrographically generated images to contoured surfaces of ceramic and glass items such as dishware Download PDFInfo
- Publication number
- US20080220188A1 US20080220188A1 US11/684,564 US68456407A US2008220188A1 US 20080220188 A1 US20080220188 A1 US 20080220188A1 US 68456407 A US68456407 A US 68456407A US 2008220188 A1 US2008220188 A1 US 2008220188A1
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- thermoplastic ink
- amorphous
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- transfer
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Links
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- 238000010438 heat treatment Methods 0.000 claims description 6
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- 125000005233 alkylalcohol group Chemical group 0.000 claims description 4
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- 238000010022 rotary screen printing Methods 0.000 description 3
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- 229910052793 cadmium Inorganic materials 0.000 description 2
- BDOSMKKIYDKNTQ-UHFFFAOYSA-N cadmium atom Chemical compound [Cd] BDOSMKKIYDKNTQ-UHFFFAOYSA-N 0.000 description 2
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- JSKIRARMQDRGJZ-UHFFFAOYSA-N dimagnesium dioxido-bis[(1-oxido-3-oxo-2,4,6,8,9-pentaoxa-1,3-disila-5,7-dialuminabicyclo[3.3.1]nonan-7-yl)oxy]silane Chemical compound [Mg++].[Mg++].[O-][Si]([O-])(O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2)O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2 JSKIRARMQDRGJZ-UHFFFAOYSA-N 0.000 description 1
- 238000010017 direct printing Methods 0.000 description 1
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- SUPCQIBBMFXVTL-UHFFFAOYSA-N ethyl 2-methylprop-2-enoate Chemical compound CCOC(=O)C(C)=C SUPCQIBBMFXVTL-UHFFFAOYSA-N 0.000 description 1
- BFMKFCLXZSUVPI-UHFFFAOYSA-N ethyl but-3-enoate Chemical compound CCOC(=O)CC=C BFMKFCLXZSUVPI-UHFFFAOYSA-N 0.000 description 1
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Images
Classifications
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47G—HOUSEHOLD OR TABLE EQUIPMENT
- A47G19/00—Table service
- A47G19/02—Plates, dishes or the like
- A47G19/025—Plates, dishes or the like with means for amusing or giving information to the user
-
- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03G—ELECTROGRAPHY; ELECTROPHOTOGRAPHY; MAGNETOGRAPHY
- G03G7/00—Selection of materials for use in image-receiving members, i.e. for reversal by physical contact; Manufacture thereof
- G03G7/0093—Image-receiving members, based on materials other than paper or plastic sheets, e.g. textiles, metals
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S428/00—Stock material or miscellaneous articles
- Y10S428/914—Transfer or decalcomania
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
- Y10T428/131—Glass, ceramic, or sintered, fused, fired, or calcined metal oxide or metal carbide containing [e.g., porcelain, brick, cement, etc.]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
Definitions
- the invention relates to method of printing on ceramic, glass-ceramic and glass, and more particularly for printing electrographically generated images to contoured surfaces of glass and ceramic items such as dishware.
- ceramic pigments are directly printed on glass and ceramic products by means of traditional printing techniques. According to such printing methods, pigments are baked into the surface of the product. As a result, a permanent printed image is obtained on the product. While this printing technique has met with some degree of success, it requires extensive manual preparation and labor. Moreover, the technique is not amenable to consistent reproduction of colors in large quantities. Among other disadvantages of such direct printing is the inability to maintain the resolution quality or the uniformity of the color printing.
- pigments are transferred via a transfer agent, such as a paper coated with gum arabic.
- a transfer agent such as a paper coated with gum arabic.
- pigments can be applied to the transfer agent by various printing techniques.
- conventional ceramic pigments can be applied to the transfer agent by screen printing, such as via rotary screen printing as illustrated in FIG. 2 .
- rotary screen printing onto ceramic, glass-ceramic and glass products is labor intensive. It also requires image reproduction by a plurality of color dispensers, each of which requires precise transfer of the resultant inks to form an image.
- image reproduction using rotary screen printing as illustrated in FIG.
- ceramic toner may be used in connection with decal transference instead of the conventional printing pigments or inks.
- the ceramic toner can be applied to the transfer agent by electrostatic or electrophotographic reproduction method. In such a process, the transfer agent is applied to the ceramic or glass article at the desired position and either moistened or heated. The transfer agent is then removed leaving the pigmented image on the article. Following the transfer, the product is fired to fuse the pigment with the product.
- a glass, glass-ceramic or ceramic dishware item having a contoured surface with an image disposed thereon is provided.
- the image is transferred to the contoured surface from a layered ink composite.
- the layered ink composite is created by depositing a first layer of thermoplastic ink onto a silicone substrate.
- a ceramic toner configured as an image is electrostatically or electrographically deposited onto the first layer of thermoplastic ink.
- a second layer of thermoplastic ink is then deposited onto the ceramic toner.
- the image is transferred, at or near ambient temperature, from the layered ink composite to the contoured surface of the dishware item by moving the second layer of thermoplastic ink and the contoured surface into contact with one another.
- the dishware item is then fired at a temperature of about 300° to 750° C.
- a layered ink composite for use in applying digital printing to a contoured ceramic, glass-ceramic or glass substrate.
- the layered ink composite includes an encapsulation layer, and image layer and a transfer layer.
- the encapsulation layer is a layer of thermoplastic ink that exhibits high permanent pressure sensitivity at room temperature.
- the encapsulation layer also exhibits a low affinity to silicone surfaces.
- the encapsulation layer is prepared from a formulation comprising a vitreous inorganic flux, either an amorphous polymer or a copolymer with an amorphous region, a plasticizer compatible with the amorphous polymer or copolymer, and an amorphous tackifying resin.
- the image layer is comprised of a ceramic toner.
- the transfer layer is a layer of thermoplastic ink that also exhibits high permanent pressure sensitivity at room temperature and a low affinity to silicone surfaces.
- the transfer layer is prepared from a formulation comprising either an amorphous polymer or copolymer with an amorphous region, a plasticizer compatible the amorphous polymer or copolymer, and an amorphous tackifying resin.
- a method of printing an electrostatically or electrographically generated image to a contoured surface of a ceramic or glass workpiece includes the step of preparing a layered ink composite. More particularly, a first layer of thermoplastic ink is deposited onto a silicone substrate. The first layer of thermoplastic ink exhibits high permanent pressure sensitivity at room temperature and a low affinity to silicone surfaces. The first layer of thermoplastic ink is prepared from a formulation comprising a vitreous inorganic flux, either an amorphous polymer or a copolymer with an amorphous region, a plasticizer compatible with the amorphous polymer or copolymer, and an amorphous tackifying resin.
- a ceramic toner is deposited onto the first layer of thermoplastic ink in a configuration that defines a desired image; the desired image having been electrostatically or electrographically generated.
- a second layer of thermoplastic ink is then deposited onto the ceramic toner.
- the second layer of thermoplastic ink also exhibits high permanent pressure sensitivity at room temperature and a low affinity to silicone surfaces.
- the second thermoplastic ink layer is prepared from a formulation comprising, either an amorphous polymer or copolymer with an amorphous region, a plasticizer compatible with the amorphous polymer or copolymer and an amorphous tackifying resin.
- the image is then transferred, at or near ambient temperature, from the layered ink composite to a contoured surface of a workpiece. Specifically, the second layer of thermoplastic ink and the contoured surface of the workpiece are moved into contact with each other.
- a printing system for printing an electrographically generated image to a contoured surface of a ceramic or glass workpiece.
- the printing system includes a cover coat print station, a transfer coat print station and a digital print engine.
- the cover coat print station is comprised of a rotatable cover coat drum and a rotatable silicone transfer roller surface.
- the rotatable cover coat drum includes a cavity for holding and dispensing thermoplastic ink.
- the cover coat drum is adapted to hold and dispense thermoplastic ink exhibiting high permanent pressure sensitivity at room temperature and a low affinity to silicone surfaces.
- the cover coat drum also includes an inking surface that can be heated to a temperature above the melting point of the thermoplastic ink with which it employed.
- the rotatable silicone transfer roller surface is disposed in proximate contact to the inking surface of the cover coat drum.
- the silicon transfer roller surface receives the thermoplastic ink from the inking surface of the cover coat drum.
- the transfer coat print station includes a rotatable transfer coat drum that has a cavity for holding and registerably dispensing thermoplastic ink.
- the transfer coat drum is suitable for use with thermoplastic ink that exhibits high permanent pressure sensitivity at room temperature and a low affinity to silicone surfaces.
- the transfer coat drum also has an inking surface that can be heated to a temperature above the melting point of the thermoplastic ink.
- the transfer coat print station also has a rotatable silicone transfer roller surface. The rotatable silicone transfer surface is disposed in proximate contact with the inking surface of the transfer coat drum. The rotatable silicone transfer surface receives thermoplastic ink from the inking surface of the transfer coat drum.
- the digital print engine is disposed between the cover coat print station and the transfer coat print station.
- the digital print engine is coupled to a ceramic toner supply container and can generate an electrostatic or electrographic image from ceramic toner.
- the digital print engine includes an image roller that transfers an electrographically generated toner image to a transfer surface.
- the digital print engine also has a rotatable silicone transfer roller surface disposed in proximate contact with the image roller. The rotatable silicone transfer surface receives the generated toner image from the image roller.
- FIG. 1 is an explanatory cross-sectional view schematically showing one embodiment of the layered ink composite with silicone transfer substrate of the present invention
- FIG. 2 is a perspective view of a prior art screen printing system
- FIG. 3 is a perspective view of a printing system according to the present invention.
- FIG. 4 is a side view of the printing section of the printing system of FIG. 3 .
- a method of printing an electrographically generated image to a contoured surface of a ceramic, glass-ceramic or glass workpiece is provided. More particularly, the method of printing can be used on contoured ceramic dishware formed and baked out of clay, porcelain, stoneware, earthenware, steatite, rutile, cordierite and cermet.
- the present invention can also be employed with glass dishware items.
- the present invention can be suitably employed with glass tableware, servingware and bakeware sold under the brand name Corelle®, or on glass items formed from a simple combination of silicates.
- the method generally includes the steps of preparing a layered ink composite 14 that includes a desired image to be transferred, transferring the image to the ceramic or glass item, and firing the item at an appropriate temperature.
- a desired image is transferred to the ceramic, glass-ceramic or glass item by building a layered ink composite 14 .
- the layered ink composite 14 includes an encapsulation layer 16 , and image layer 18 and a transfer layer 20 .
- the encapsulation layer 16 is a thermoplastic ink that exhibits high permanent pressure sensitivity at room temperature.
- the encapsulation layer 16 also exhibits a low affinity to silicone surfaces.
- the encapsulation layer 16 is prepared from a formulation comprising a vitreous inorganic flux, either an amorphous polymer or a copolymer with an amorphous region, a plasticizer compatible with the amorphous polymer or copolymer, and an amorphous tackifying resin.
- the image layer 18 is comprised of a ceramic toner 18 .
- the transfer layer 20 is a thermoplastic ink that also exhibits high permanent pressure sensitivity at room temperature and a low affinity to silicone surfaces.
- the transfer layer 20 is prepared from a formulation comprising either an amorphous polymer or copolymer with an amorphous region, a plasticizer compatible the amorphous polymer or copolymer, and an amorphous tackifying resin.
- thermoplastic ink 16 is deposited onto a silicone transfer substrate 22 .
- a ceramic toner 18 is then deposited onto the first layer of thermoplastic ink 16 in a configuration that defines a desired electrostatically or electrographically generated image.
- a second layer of thermoplastic ink 20 is then deposited onto the ceramic toner 18 .
- the image is then transferred, at or near ambient temperature, from the layered ink composite 14 to a contoured surface of a workpiece 12 .
- the second layer of thermoplastic ink 20 and the contoured surface of the workpiece 12 are moved into contact with each other.
- the workpiece 12 bearing the desired image, is then fired to cure the workpiece 12 .
- the preferred structure of the layered ink composite 14 will now be described.
- the first layer of thermoplastic ink 16 is of the type particularly useful in those printing processes in which a transfer member is employed to print successive colors onto a transfer membrane which then transfers the multicolored print to the item.
- the first layer of thermoplastic ink 16 is of the type described in U.S. Pat. No. 4,472,537 which is incorporated by reference herein.
- the first layer of thermoplastic ink 16 or, the encapsulation layer 16 exhibits high permanent pressure sensitivity at or near room temperature and a low affinity to silicone surfaces.
- the first layer of thermoplastic ink 16 also exhibits high cohesive strength and high thermal stability. These properties enable the first layer of thermoplastic ink 16 to be readily transferred between surfaces for which it has differing degrees of affinity. Further, it permits release of the first layer of thermoplastic ink 16 from the transferring surface with much greater ease than any currently available formulation.
- the first layer of thermoplastic ink 16 preferably exhibits high tack and cohesive strength when cooled to a solid or semi-solid (high viscosity) state.
- the first layer of thermoplastic ink 16 will, in effect, form a cover coating to “encapsulate” the ceramic toner 18 that defines the desired image.
- the first layer of thermoplastic ink 16 will assist in minimizing any cadmium release emanating from the ceramic toner 18 .
- the first layer of thermoplastic ink 16 will also provide a glossy finish to the design-bearing surface of the workpiece 12 ; whereas, the absence of such an encapsulating layer generally results in an relatively dull finish.
- a method for eliminating the discoloration resulting from carbonaceous residue be employed to maintain the clarity of the first layer of thermoplastic ink 16 .
- the method described in U.S. Pat. No. 5,149,565 (incorporated herein by reference) be employed.
- the first layer of thermoplastic ink 16 is preferably formulated from amorphous organic polymers or copolymers with amorphous regions, with low molecular weight tackifying resins and plasticizers.
- the primary purpose of the plasticizers is to adjust melt viscosity, but, where carefully selected, they can also be useful in enhancing the level of tack. It is preferable that low-to-medium molecular weight polymers are employed in connection with the present invention.
- the first layer of thermoplastic ink 16 is prepared from a formulation consisting essentially, in weight percent, of: (a) about 50 to 80% of a pigmented vitreous, inorganic flux; (b) about 2 to 20% of a cohesive strength imparting polymer with an average molecular weight of 4,000 to 200,000, wherein said polymer is selected from the group of ethylene copolymers with vinyl esters or vinyl acids, polyalkyl acrylate, polyalkyl methacrylate, polyalkyl acrylate or polyalkyl methacrylate or styrene copolymers with acrylic or methacrylic acid, styrene block copolymers with butadiene, cellulosic ethers, amorphous polyolefins, polyvinylpyrrolidone, polyethers, and polyesters; (c) about 5 to 25% of a plasticizer with an average molecular weight of 200 to 5000 which is compatible with said polymer selected from the group of alky
- Particularly desirable organic polymers include polymethylmethacrylate, polybutylmethacrylate, ethylvinyl acetate, ethyl methacrylate, and an amorphous polyolefin selected from the group of polyisobutylene and atacetic polypropylene.
- a copolymer can be employed.
- a particularly desirable rosin derivative for an amorphous tackifying resin is an ester derivative of hydrogenated rosin, the most preferred rosin derivative being selected from group of glycerol ester and pentaerythritol ester.
- the second layer, or the image layer 18 is generally comprised of ceramic toner 18 .
- the ceramic toner 18 is comprised of ceramic dye compositions of the kind described in U.S. Pat. No. 5,948,471 that include fine particles of ceramic pigments and suitable binding medium resins.
- the preferable ceramic pigments generally include inorganic materials that exhibit a high degree of temperature stability such that they are suitable for fireproof or fire-resistant coloring of ceramic or glass products. Additionally, it is preferable that the ceramic pigments exhibit a high degree of refractability.
- any ceramic toner 18 suitable for deposition using electrostatic or electrographic methods can be employed without departing from the present invention.
- the third layer of the layered ink composite 14 is also generally comprised of thermoplastic ink.
- the transfer layer 20 is provided as a chemical vehicle for transferring the toner 18 ink design and encapsulation layer 16 from the silicone transfer substrate 22 to the ceramic or glass workpiece 12 .
- the third layer of thermoplastic ink will exhibit sufficient tack to cause adherence to the ceramic or glass workpiece 12 upon contact, and still provide sufficient cohesive strength to adhere to the silicone transfer substrate 22 .
- this second layer of thermoplastic ink 20 has the same characteristics and is similar in formulation to the first layer of thermoplastic ink 16 .
- the transfer layer 20 also preferably exhibits relatively high permanent pressure sensitivity at room temperature and a relatively low affinity to silicone surfaces.
- the second thermoplastic ink layer (i.e., the transfer layer) 20 is preferably prepared from a formulation that includes either an amorphous polymer or copolymer with an amorphous region, a plasticizer compatible with the amorphous polymer (or copolymer with an amorphous region), and an amorphous tackifying resin.
- the second layer of thermoplastic ink 20 is prepared from a formulation consisting essentially, in weight percent, of: (a) about 2 to 20% of a cohesive strength imparting polymer with an average molecular weight of 10,000 to 200,000, wherein said polymer is selected from the group of ethylene copolymers with vinyl esters or vinyl acids, polyalkyl acrylate, polyalkyl methacrylate, polyalkyl acrylate or polyalkyl methacrylate or styrene copolymers with acrylic or methacrylic acid, styrene block copolymers with butadiene, cellulosic ethers, amorphous polyolefins, polyvinylpyrrolidone, polyethers, and polyesters; (b) about 5 to 25% of a plasticizer with an average molecular weight of 200 to 5000 which is compatible with said polymer selected from the group of alkylene glycol or glycerol esters of monocarboxylic acids, alkyl alcohol esters, and polyester
- the layered ink composite 14 is transferred from a flexible silicone transfer substrate 22 .
- the silicone transfer substrate 22 will preferably have release characteristics to allow the design as collected in the layered ink composite 14 to be deposited onto the ceramic, glass-ceramic or glass surface of a workpiece 12 .
- the silicone transfer substrate 22 is of the type disclosed in U.S. Pat. No. 4,532,175 which is incorporated herein by reference.
- the silicone transfer substrate 22 be formed from any formulation and using any method suitable for providing the release characteristics described herein.
- a printing system 24 for printing an electrostatically or electrographically generated image in accordance with the method described above is also provided.
- the system generally includes a cover coat print station 26 , a digital print engine 28 and a transfer coat print station 30 .
- the cover coat print station 26 , the digital print engine 28 and the transfer coat print station 30 are generally disposed in series such that the workpiece 12 may move from station to station in an “assembly line” fashion.
- the system 24 also preferably includes a conveyor assembly 32 positioned below the stations suitable for transporting the silicone transfer substrate 22 between the stations is positioned below.
- the conveyor 32 is preferably coupled to a control system that allows incremental indexing at each of the print stations 26 , 28 , 30 to accommodate the deposition of materials as appropriate.
- the cover coat print station 26 is provided to apply the first layer of thermoplastic ink 16 (i.e., the encapsulation layer) to the silicone transfer substrate 22 .
- the cover coat print station 26 includes a rotatable cover coat drum 34 and a rotatable silicone transfer roller surface 38 .
- the cover coat drum 34 includes a cavity for holding and dispensing thermoplastic ink exhibiting the characteristics described herein.
- the thermoplastic ink is heated to a temperature above its melting point so that it may be inserted into the cover coat drum 34 in liquid form.
- the cover coat drum 34 also includes an inking surface 36 that can be heated to a temperature in excess of the melting point of the thermoplastic ink.
- the thermoplastic ink can maintain its liquid consistency such that it may be deposited in appropriate quantities onto the rotatable silicone transfer roller surface 38 .
- the thermoplastic ink 16 is heated to a temperature of between 90° to 170° C. prior to the step of depositing the second layer of thermoplastic ink onto the ceramic toner.
- the thermoplastic ink 16 is heated to a temperature of between 139° to 156° C.
- the inking surface 36 of the cover coat drum 34 can include a plurality apertures that are disposed in the configuration of the desired image.
- inks that require heating to temperatures lower than their melting point, or which require no heating (i.e. sufficiently liquid at ambient), to maintain suitable viscosity and characteristics required for transfer and printing may be employed with the present invention.
- thermoplastic ink 16 flowing from the drum will be deposited onto the rotatable silicone transfer roller surface 38 in a configuration that mirrors the desired image.
- the apertures may be employed in the inking surface 36 of the cover coat drum 34 can assume any configuration suitable to dispense the thermoplastic ink within the cavity onto the silicone transfer roller surface 38 .
- the rotatable silicone transfer roller surface 38 receives thermoplastic ink 16 from the inking surface 36 of the cover coat drum 34 and is thusly disposed in proximate contact with the inking surface 36 of the cover coat drum 34 .
- the silicone transfer roller surface 38 can assume the form of a drum. More specifically, it is contemplated that the silicone transfer roller surface 38 is a sheet of sufficient flexibility to be attached to a drum core. However, the silicone transfer surface 38 can be a drum made substantially of silicone material or materials. In any instance, the silicone transfer roller surface 38 will preferably have characteristics to allow the transfer roller surface 38 to collect the thermoplastic ink from the adjacently disposed inking surface 36 of the cover coat drum 34 .
- the transfer roller surface 38 will preferably have release characteristics that allow the ink 16 to be subsequently deposited onto the silicone transfer substrate 22 .
- the silicone transfer roller surfaces 38 are typically and preferably maintained at temperatures in excess of the ambient temperature.
- the system includes a second cover coat print station 26 .
- a second encapsulation layer 16 may be deposited on the first encapsulation layer 16 to increase the overall encapsulation qualities of the layered ink composite 14 .
- the second cover coat print station 26 can be configured as a redundant print station used when the first cover coat print station 26 is non-operational.
- the second cover coat print station 26 includes a rotatable cover coat drum 34 and a rotatable silicone transfer roller surface 38 as described above.
- a transfer coat print station 30 is provided to apply second layer of thermoplastic ink 20 (i.e., the transfer layer) to the layered ink composite 14 .
- the transfer coat print station 30 includes a rotatable transfer coat drum 46 and a rotatable silicone transfer roller surface 38 .
- the transfer coat drum 46 includes a cavity for holding and dispensing thermoplastic ink 20 exhibiting the characteristics described herein.
- the thermoplastic ink 20 is heated to a temperature above its melting point so that it may be inserted into the transfer coat drum 46 in liquid form.
- the transfer coat drum 46 also includes an inking surface 36 that can be heated to a temperature in excess of the melting point of the thermoplastic ink 26 .
- the thermoplastic ink 20 can maintain its liquid consistency such that it may be deposited in appropriate quantities onto the rotatable silicone transfer roller surface 38 .
- the thermoplastic ink 18 is heated to a temperature of between 90 to 170° C. prior to the step of depositing the second layer of thermoplastic ink onto the ceramic toner.
- the thermoplastic ink 18 is heated to a temperature of between 139 to 156° C.
- the inking surface 36 of the transfer coat drum 46 can include a plurality apertures that are disposed generally in the configuration of the desired image.
- inks that require heating to temperatures lower than their melting point, or which require no heating (i.e. sufficiently liquid at ambient), to maintain suitable viscosity and characteristics required for transfer and printing may be employed with the present invention.
- thermoplastic ink flowing from the transfer coat drum 46 will be deposited onto the rotatable silicone transfer roller surface 38 in a configuration that mirrors the desired image.
- the apertures in the inking surface 36 of the transfer coat drum 46 be employed, and can assume any configuration suitable to dispense the thermoplastic ink 20 within the cavity onto the silicone transfer roller surface 38 .
- the rotatable silicone transfer roller surface 38 receives thermoplastic ink from the inking surface 36 of the transfer coat drum 46 and is thusly disposed in proximate contact with the inking surface 36 of the transfer coat drum 38 .
- the silicone transfer roller surface 38 can assume the form of a drum. More specifically, it is contemplated that the silicone transfer roller surface 38 is a sheet of sufficient flexibility to be attached to a drum core. However, the silicone transfer surface 38 can be a drum made substantially of silicone material or materials. In any instance, the silicone transfer roller surface 38 will preferably have characteristics to allow the transfer roller surface 38 to collect the thermoplastic ink 20 from the adjacently disposed inking surface 36 of the cover coat drum 34 .
- the transfer roller surface 38 will preferably have release characteristics that allow the ink 20 to be subsequently deposited onto the silicone transfer substrate 22 .
- the silicone transfer roller surfaces 38 are typically and preferably maintained a temperatures in excess of the ambient temperature.
- the digital print engine 28 is disposed between the cover coat print station 26 and the transfer coat print station 30 .
- the digital print engine 28 of the present invention is coupled to a ceramic toner supply 40 and can generate an electrostatic electrographic image from ceramic toner 18 .
- the ceramic toner supply 40 will include ceramic toners 18 with colored pigments that allow the system to print multi-color images.
- the digital print engine 28 of the present invention will generally include an image roller 42 and a rotatable silicone transfer roller surface 38 . According to the present invention, however, the image roller 42 transfers the electrographically generated toner 18 image to the adjacent transfer roller surface 38 .
- digital printers capable of electrostatic or electrographic image printing using ceramic toner 18 s is known in the art.
- the digital print engine 28 may be of the types offered by data M Software & Engineering GmbH, Oberlaindern, Germany.
- the rotatable silicone transfer roller surface 38 of the print engine 28 station is positioned adjacent to, and in proximate contact with, the image roller 42 .
- the rotatable elastomeric transfer roller surface 38 receives the generated toner image (formed from the ceramic toner 18 ) from the image roller 42 .
- the rotatable silicone transfer roller surface 38 can again assume the form of a drum. More specifically, it is contemplated that the silicone transfer roller surface 38 is a sheet of sufficient flexibility to be attached to a drum core.
- the silicone transfer drum can be a drum made substantially of silicone material or materials.
- the silicone transfer roller surface 38 will preferably have characteristics to allow the transfer roller surface 38 to collect the ceramic toner 18 from the adjacently disposed image roller 42 .
- the silicone transfer roller surface 38 will also preferably have release characteristics that allow the ceramic toner 18 to be subsequently deposited onto the silicone transfer substrate 22 .
- the silicone transfer roller surfaces 38 are typically maintained a temperatures in excess of the ambient temperature.
- the present system preferably includes a conveyor assembly 32 suitable for transporting the silicone transfer substrate 22 between the stations.
- the conveyor assembly 32 generally runs below the stations such that it is positioned proximate the each of the rotatable silicone transfer roller surfaces 38 .
- the silicone transfer substrate 22 can be advanced between the transfer roller surfaces 38 of the cover coat print station 26 , the digital print engine 28 and the transfer coat print station 30 .
- the workpiece 12 and silicone transfer substrate 22 , with layered ink composite 14 can then be transported by known methods to a printing station 44 which will include a printing die 46 .
- a printing station 44 which will include a printing die 46 .
- the silicone transfer substrate 22 and layered ink composite 14 is positioned such that the image faces the workpiece 12 .
- the printing die 46 can then be displaced, by known drive mechanisms, to move the silicone transfer substrate 22 , with the image formed from the layered ink composite 14 , into contact with the surface of the workpiece 12 to be imprinted with the image.
- the image is thereby transferred at, or near, ambient temperature from the layered ink composite 14 to the contoured surface of the workpiece 12 .
- an image can be applied to a contoured glass or ceramic dishware item.
- the image is transferred from a layered ink composite 14 created by (1) depositing a first layer of thermoplastic ink 16 onto a silicone transfer substrate 22 ; (2) depositing ceramic toner 18 onto the first layer of thermoplastic ink 16 , the deposited ceramic toner 18 configured as an electrographically generated image; (3) depositing a second layer of thermoplastic ink 20 onto the ceramic toner 18 ; (4) transferring the image, at or near ambient temperature, from the layered ink composite 14 to the contoured surface of the dishware item by moving either the second layer of thermoplastic ink 20 or the contoured surface of the dishware item into contact with the other; and, (5) firing the dishware item, preferably at a temperature of about 300° to about 750° C.
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Abstract
Description
- This application claims priority from U.S. Provisional Application No. 60/894,053, which is incorporated herein by reference.
- The invention relates to method of printing on ceramic, glass-ceramic and glass, and more particularly for printing electrographically generated images to contoured surfaces of glass and ceramic items such as dishware.
- It is well known to apply designs to ceramic, glass-ceramic and glass products such as, for example, tableware, bakeware and other dishware to esthetically enhance the appearance of the product. Several methods have been employed for applying designs to such products.
- According to one process, ceramic pigments are directly printed on glass and ceramic products by means of traditional printing techniques. According to such printing methods, pigments are baked into the surface of the product. As a result, a permanent printed image is obtained on the product. While this printing technique has met with some degree of success, it requires extensive manual preparation and labor. Moreover, the technique is not amenable to consistent reproduction of colors in large quantities. Among other disadvantages of such direct printing is the inability to maintain the resolution quality or the uniformity of the color printing.
- Another known process for printing to ceramic, glass-ceramic and glass products relies on the technique of decal image transference. Typically, pigments are transferred via a transfer agent, such as a paper coated with gum arabic. In decal image transference, pigments can be applied to the transfer agent by various printing techniques. For example, conventional ceramic pigments can be applied to the transfer agent by screen printing, such as via rotary screen printing as illustrated in
FIG. 2 . However, rotary screen printing onto ceramic, glass-ceramic and glass products is labor intensive. It also requires image reproduction by a plurality of color dispensers, each of which requires precise transfer of the resultant inks to form an image. Moreover, image reproduction using rotary screen printing, as illustrated inFIG. 2 , typically requires the addition of heat to set an image transferred to the workpiece. Alternatively, ceramic toner may be used in connection with decal transference instead of the conventional printing pigments or inks. In these instances, the ceramic toner can be applied to the transfer agent by electrostatic or electrophotographic reproduction method. In such a process, the transfer agent is applied to the ceramic or glass article at the desired position and either moistened or heated. The transfer agent is then removed leaving the pigmented image on the article. Following the transfer, the product is fired to fuse the pigment with the product. - While the decal image transference technique has also had some degree of success, it also has certain inherent disadvantages. One disadvantage is that the image must be printed on discrete sheets of the transfer agent that must be manipulated during further processing. Thus, the printing process is inherently less efficient than an otherwise automated process would be. Moreover, because each transfer agent sheet requires separate handling, consistent reproducibility of the image is extremely difficult.
- Another process for printing to ceramic and glass products is described in U.S. Pat. Nos. 6,487,386 and 6,745,684 in which electrostatic or electrophotographic methods are used in a process to apply ceramic toner directly to the ceramic or glass product. The processes described in each of these patents also have inherent drawbacks. One particular drawback is the inability to permanently affix the image to a ceramic or glass product at or near ambient temperatures, without application of additional heat. Another of the drawbacks of the processes described in U.S. Pat. Nos. 6,487,386 and 6,745,684 is that they do not provide for an overcoat to retard cadmium release or maximize gloss.
- The present invention is provided to solve the problems discussed above and other problems, and to provide advantages and aspects not previously provided. A full discussion of the features and advantages of the present invention is deferred to the following detailed description, which proceeds with reference to the accompanying drawings.
- According to the present invention, a glass, glass-ceramic or ceramic dishware item having a contoured surface with an image disposed thereon is provided. The image is transferred to the contoured surface from a layered ink composite. The layered ink composite is created by depositing a first layer of thermoplastic ink onto a silicone substrate. A ceramic toner configured as an image is electrostatically or electrographically deposited onto the first layer of thermoplastic ink. A second layer of thermoplastic ink is then deposited onto the ceramic toner. The image is transferred, at or near ambient temperature, from the layered ink composite to the contoured surface of the dishware item by moving the second layer of thermoplastic ink and the contoured surface into contact with one another. The dishware item is then fired at a temperature of about 300° to 750° C.
- According to another aspect of the present invention, a layered ink composite for use in applying digital printing to a contoured ceramic, glass-ceramic or glass substrate is provided. The layered ink composite includes an encapsulation layer, and image layer and a transfer layer. The encapsulation layer is a layer of thermoplastic ink that exhibits high permanent pressure sensitivity at room temperature. The encapsulation layer also exhibits a low affinity to silicone surfaces. The encapsulation layer is prepared from a formulation comprising a vitreous inorganic flux, either an amorphous polymer or a copolymer with an amorphous region, a plasticizer compatible with the amorphous polymer or copolymer, and an amorphous tackifying resin. The image layer is comprised of a ceramic toner. The transfer layer is a layer of thermoplastic ink that also exhibits high permanent pressure sensitivity at room temperature and a low affinity to silicone surfaces. The transfer layer is prepared from a formulation comprising either an amorphous polymer or copolymer with an amorphous region, a plasticizer compatible the amorphous polymer or copolymer, and an amorphous tackifying resin.
- According to another aspect of the present invention, a method of printing an electrostatically or electrographically generated image to a contoured surface of a ceramic or glass workpiece is provided. The method includes the step of preparing a layered ink composite. More particularly, a first layer of thermoplastic ink is deposited onto a silicone substrate. The first layer of thermoplastic ink exhibits high permanent pressure sensitivity at room temperature and a low affinity to silicone surfaces. The first layer of thermoplastic ink is prepared from a formulation comprising a vitreous inorganic flux, either an amorphous polymer or a copolymer with an amorphous region, a plasticizer compatible with the amorphous polymer or copolymer, and an amorphous tackifying resin. A ceramic toner is deposited onto the first layer of thermoplastic ink in a configuration that defines a desired image; the desired image having been electrostatically or electrographically generated. A second layer of thermoplastic ink is then deposited onto the ceramic toner. The second layer of thermoplastic ink also exhibits high permanent pressure sensitivity at room temperature and a low affinity to silicone surfaces. The second thermoplastic ink layer is prepared from a formulation comprising, either an amorphous polymer or copolymer with an amorphous region, a plasticizer compatible with the amorphous polymer or copolymer and an amorphous tackifying resin. The image is then transferred, at or near ambient temperature, from the layered ink composite to a contoured surface of a workpiece. Specifically, the second layer of thermoplastic ink and the contoured surface of the workpiece are moved into contact with each other.
- According to still another aspect of the present invention, a printing system for printing an electrographically generated image to a contoured surface of a ceramic or glass workpiece is provided. The printing system includes a cover coat print station, a transfer coat print station and a digital print engine.
- The cover coat print station is comprised of a rotatable cover coat drum and a rotatable silicone transfer roller surface. The rotatable cover coat drum includes a cavity for holding and dispensing thermoplastic ink. In particular, the cover coat drum is adapted to hold and dispense thermoplastic ink exhibiting high permanent pressure sensitivity at room temperature and a low affinity to silicone surfaces. The cover coat drum also includes an inking surface that can be heated to a temperature above the melting point of the thermoplastic ink with which it employed. The rotatable silicone transfer roller surface is disposed in proximate contact to the inking surface of the cover coat drum. The silicon transfer roller surface receives the thermoplastic ink from the inking surface of the cover coat drum.
- The transfer coat print station includes a rotatable transfer coat drum that has a cavity for holding and registerably dispensing thermoplastic ink. In particular, the transfer coat drum is suitable for use with thermoplastic ink that exhibits high permanent pressure sensitivity at room temperature and a low affinity to silicone surfaces. The transfer coat drum also has an inking surface that can be heated to a temperature above the melting point of the thermoplastic ink. The transfer coat print station also has a rotatable silicone transfer roller surface. The rotatable silicone transfer surface is disposed in proximate contact with the inking surface of the transfer coat drum. The rotatable silicone transfer surface receives thermoplastic ink from the inking surface of the transfer coat drum.
- The digital print engine is disposed between the cover coat print station and the transfer coat print station. The digital print engine is coupled to a ceramic toner supply container and can generate an electrostatic or electrographic image from ceramic toner. The digital print engine includes an image roller that transfers an electrographically generated toner image to a transfer surface. The digital print engine also has a rotatable silicone transfer roller surface disposed in proximate contact with the image roller. The rotatable silicone transfer surface receives the generated toner image from the image roller.
- Other features and advantages of the invention will be apparent from the following specification taken in conjunction with the following drawings.
- To understand the present invention, it will now be described by way of example, with reference to the accompanying drawings in which:
-
FIG. 1 is an explanatory cross-sectional view schematically showing one embodiment of the layered ink composite with silicone transfer substrate of the present invention; -
FIG. 2 is a perspective view of a prior art screen printing system; -
FIG. 3 is a perspective view of a printing system according to the present invention; and, -
FIG. 4 is a side view of the printing section of the printing system ofFIG. 3 . - The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present invention.
- While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated.
- According to one embodiment, a method of printing an electrographically generated image to a contoured surface of a ceramic, glass-ceramic or glass workpiece is provided. More particularly, the method of printing can be used on contoured ceramic dishware formed and baked out of clay, porcelain, stoneware, earthenware, steatite, rutile, cordierite and cermet. The present invention can also be employed with glass dishware items. For example, the present invention can be suitably employed with glass tableware, servingware and bakeware sold under the brand name Corelle®, or on glass items formed from a simple combination of silicates. Referring now to FIGS. 1 and 3-4, the method generally includes the steps of preparing a
layered ink composite 14 that includes a desired image to be transferred, transferring the image to the ceramic or glass item, and firing the item at an appropriate temperature. - As shown in
FIG. 1 , a desired image is transferred to the ceramic, glass-ceramic or glass item by building alayered ink composite 14. Thelayered ink composite 14 includes anencapsulation layer 16, andimage layer 18 and atransfer layer 20. As will also be discussed in further detail herein, theencapsulation layer 16 is a thermoplastic ink that exhibits high permanent pressure sensitivity at room temperature. Theencapsulation layer 16 also exhibits a low affinity to silicone surfaces. Theencapsulation layer 16 is prepared from a formulation comprising a vitreous inorganic flux, either an amorphous polymer or a copolymer with an amorphous region, a plasticizer compatible with the amorphous polymer or copolymer, and an amorphous tackifying resin. Theimage layer 18 is comprised of aceramic toner 18. As will also be discussed in further detail herein, thetransfer layer 20 is a thermoplastic ink that also exhibits high permanent pressure sensitivity at room temperature and a low affinity to silicone surfaces. Thetransfer layer 20 is prepared from a formulation comprising either an amorphous polymer or copolymer with an amorphous region, a plasticizer compatible the amorphous polymer or copolymer, and an amorphous tackifying resin. - As shown in
FIG. 1 , a first layer ofthermoplastic ink 16 is deposited onto asilicone transfer substrate 22. Aceramic toner 18 is then deposited onto the first layer ofthermoplastic ink 16 in a configuration that defines a desired electrostatically or electrographically generated image. A second layer ofthermoplastic ink 20 is then deposited onto theceramic toner 18. The image is then transferred, at or near ambient temperature, from the layeredink composite 14 to a contoured surface of aworkpiece 12. Specifically, the second layer ofthermoplastic ink 20 and the contoured surface of theworkpiece 12 are moved into contact with each other. Theworkpiece 12, bearing the desired image, is then fired to cure theworkpiece 12. The preferred structure of thelayered ink composite 14 will now be described. - The first layer of
thermoplastic ink 16 is of the type particularly useful in those printing processes in which a transfer member is employed to print successive colors onto a transfer membrane which then transfers the multicolored print to the item. Preferably, the first layer ofthermoplastic ink 16 is of the type described in U.S. Pat. No. 4,472,537 which is incorporated by reference herein. According to the present invention, the first layer ofthermoplastic ink 16 or, theencapsulation layer 16, exhibits high permanent pressure sensitivity at or near room temperature and a low affinity to silicone surfaces. The first layer ofthermoplastic ink 16 also exhibits high cohesive strength and high thermal stability. These properties enable the first layer ofthermoplastic ink 16 to be readily transferred between surfaces for which it has differing degrees of affinity. Further, it permits release of the first layer ofthermoplastic ink 16 from the transferring surface with much greater ease than any currently available formulation. - More specifically, according to the present invention, the first layer of
thermoplastic ink 16 preferably exhibits high tack and cohesive strength when cooled to a solid or semi-solid (high viscosity) state. When thelayered ink composite 14 is ultimately contacted with the contoured surface of theworkpiece 12, the first layer ofthermoplastic ink 16 will, in effect, form a cover coating to “encapsulate” theceramic toner 18 that defines the desired image. As such, the first layer ofthermoplastic ink 16 will assist in minimizing any cadmium release emanating from theceramic toner 18. - The first layer of
thermoplastic ink 16 will also provide a glossy finish to the design-bearing surface of theworkpiece 12; whereas, the absence of such an encapsulating layer generally results in an relatively dull finish. Thus, it is preferable that a method for eliminating the discoloration resulting from carbonaceous residue be employed to maintain the clarity of the first layer ofthermoplastic ink 16. For example, it is contemplated that the method described in U.S. Pat. No. 5,149,565 (incorporated herein by reference) be employed. - The first layer of
thermoplastic ink 16 is preferably formulated from amorphous organic polymers or copolymers with amorphous regions, with low molecular weight tackifying resins and plasticizers. The primary purpose of the plasticizers is to adjust melt viscosity, but, where carefully selected, they can also be useful in enhancing the level of tack. It is preferable that low-to-medium molecular weight polymers are employed in connection with the present invention. In one preferred embodiment, the first layer of thermoplastic ink 16 is prepared from a formulation consisting essentially, in weight percent, of: (a) about 50 to 80% of a pigmented vitreous, inorganic flux; (b) about 2 to 20% of a cohesive strength imparting polymer with an average molecular weight of 4,000 to 200,000, wherein said polymer is selected from the group of ethylene copolymers with vinyl esters or vinyl acids, polyalkyl acrylate, polyalkyl methacrylate, polyalkyl acrylate or polyalkyl methacrylate or styrene copolymers with acrylic or methacrylic acid, styrene block copolymers with butadiene, cellulosic ethers, amorphous polyolefins, polyvinylpyrrolidone, polyethers, and polyesters; (c) about 5 to 25% of a plasticizer with an average molecular weight of 200 to 5000 which is compatible with said polymer selected from the group of alkylene glycol or glycerol esters of monocarboxylic acids, alkyl alcohol esters of mono-, di-, and tricarboxylic acids, polyesters of dicarboxylic acids and polyols, polyalkylene glycols, glyceryl triepoxy acetoxy stearate, polybutene, mineral oil, and epoxidized vegetable oils; and (d) about 2 to 20% of an amorphous tackifying resin with an average molecular weight of 500 to 10,000 and a ring and ball softening point of 35° to 115° C. selected from the group of hydrocarbon resins, terpenes, phenolics, rosin, and rosin derivatives. - Particularly desirable organic polymers include polymethylmethacrylate, polybutylmethacrylate, ethylvinyl acetate, ethyl methacrylate, and an amorphous polyolefin selected from the group of polyisobutylene and atacetic polypropylene. Alternatively, a copolymer can be employed. A particularly desirable rosin derivative for an amorphous tackifying resin is an ester derivative of hydrogenated rosin, the most preferred rosin derivative being selected from group of glycerol ester and pentaerythritol ester.
- The second layer, or the
image layer 18, is generally comprised ofceramic toner 18. Preferably theceramic toner 18 is comprised of ceramic dye compositions of the kind described in U.S. Pat. No. 5,948,471 that include fine particles of ceramic pigments and suitable binding medium resins. More specifically, the preferable ceramic pigments generally include inorganic materials that exhibit a high degree of temperature stability such that they are suitable for fireproof or fire-resistant coloring of ceramic or glass products. Additionally, it is preferable that the ceramic pigments exhibit a high degree of refractability. However, it will be understood by one of ordinary skill in the art that anyceramic toner 18 suitable for deposition using electrostatic or electrographic methods can be employed without departing from the present invention. - The third layer of the
layered ink composite 14, or thetransfer layer 20, is also generally comprised of thermoplastic ink. Thetransfer layer 20 is provided as a chemical vehicle for transferring thetoner 18 ink design andencapsulation layer 16 from thesilicone transfer substrate 22 to the ceramic orglass workpiece 12. Thus it will be understood that the third layer of thermoplastic ink will exhibit sufficient tack to cause adherence to the ceramic orglass workpiece 12 upon contact, and still provide sufficient cohesive strength to adhere to thesilicone transfer substrate 22. - In a preferred embodiment, this second layer of
thermoplastic ink 20 has the same characteristics and is similar in formulation to the first layer ofthermoplastic ink 16. For example, thetransfer layer 20 also preferably exhibits relatively high permanent pressure sensitivity at room temperature and a relatively low affinity to silicone surfaces. Further, the second thermoplastic ink layer (i.e., the transfer layer) 20 is preferably prepared from a formulation that includes either an amorphous polymer or copolymer with an amorphous region, a plasticizer compatible with the amorphous polymer (or copolymer with an amorphous region), and an amorphous tackifying resin. - In one preferred embodiment, the second layer of
thermoplastic ink 20 is prepared from a formulation consisting essentially, in weight percent, of: (a) about 2 to 20% of a cohesive strength imparting polymer with an average molecular weight of 10,000 to 200,000, wherein said polymer is selected from the group of ethylene copolymers with vinyl esters or vinyl acids, polyalkyl acrylate, polyalkyl methacrylate, polyalkyl acrylate or polyalkyl methacrylate or styrene copolymers with acrylic or methacrylic acid, styrene block copolymers with butadiene, cellulosic ethers, amorphous polyolefins, polyvinylpyrrolidone, polyethers, and polyesters; (b) about 5 to 25% of a plasticizer with an average molecular weight of 200 to 5000 which is compatible with said polymer selected from the group of alkylene glycol or glycerol esters of monocarboxylic acids, alkyl alcohol esters of mono-, di-, and tricarboxylic acids, polyesters of dicarboxylic acids and polyols, polyalkylene glycols, glyceryl triepoxy acetoxy stearate, polybutene, mineral oil, and epoxidized vegetable oils; and (c) about 2 to 20% of an amorphous tackifying resin with an average molecular weight of 500 to 10,000 and a ring and ball softening point of 35° to 115° C. selected from the group of hydrocarbon resins, terpenes, phenolics, rosin, and rosin derivatives. In one embodiment of the present invention, theencapsulation layer 16 also includes a vitreous organic flux. - As discussed above, according to a preferred embodiment of the present invention, the
layered ink composite 14 is transferred from a flexiblesilicone transfer substrate 22. Thesilicone transfer substrate 22 will preferably have release characteristics to allow the design as collected in thelayered ink composite 14 to be deposited onto the ceramic, glass-ceramic or glass surface of aworkpiece 12. Preferably, thesilicone transfer substrate 22 is of the type disclosed in U.S. Pat. No. 4,532,175 which is incorporated herein by reference. However, it is contemplated that thesilicone transfer substrate 22 be formed from any formulation and using any method suitable for providing the release characteristics described herein. - According to the present invention, a
printing system 24 for printing an electrostatically or electrographically generated image in accordance with the method described above is also provided. As shown inFIGS. 4-5 , the system generally includes a covercoat print station 26, adigital print engine 28 and a transfercoat print station 30. In one embodiment, the covercoat print station 26, thedigital print engine 28 and the transfercoat print station 30 are generally disposed in series such that theworkpiece 12 may move from station to station in an “assembly line” fashion. Thesystem 24 also preferably includes aconveyor assembly 32 positioned below the stations suitable for transporting thesilicone transfer substrate 22 between the stations is positioned below. Theconveyor 32 is preferably coupled to a control system that allows incremental indexing at each of theprint stations - The cover
coat print station 26 is provided to apply the first layer of thermoplastic ink 16 (i.e., the encapsulation layer) to thesilicone transfer substrate 22. As shown inFIGS. 4 and 5 , the covercoat print station 26 includes a rotatablecover coat drum 34 and a rotatable siliconetransfer roller surface 38. Thecover coat drum 34 includes a cavity for holding and dispensing thermoplastic ink exhibiting the characteristics described herein. Preferably, the thermoplastic ink is heated to a temperature above its melting point so that it may be inserted into thecover coat drum 34 in liquid form. Thecover coat drum 34 also includes an inking surface 36 that can be heated to a temperature in excess of the melting point of the thermoplastic ink. Thus, the thermoplastic ink can maintain its liquid consistency such that it may be deposited in appropriate quantities onto the rotatable siliconetransfer roller surface 38. Preferably, thethermoplastic ink 16 is heated to a temperature of between 90° to 170° C. prior to the step of depositing the second layer of thermoplastic ink onto the ceramic toner. And, most preferably, thethermoplastic ink 16 is heated to a temperature of between 139° to 156° C. The inking surface 36 of thecover coat drum 34 can include a plurality apertures that are disposed in the configuration of the desired image. However, it is contemplated that inks that require heating to temperatures lower than their melting point, or which require no heating (i.e. sufficiently liquid at ambient), to maintain suitable viscosity and characteristics required for transfer and printing may be employed with the present invention. - The
thermoplastic ink 16 flowing from the drum will be deposited onto the rotatable siliconetransfer roller surface 38 in a configuration that mirrors the desired image. However, it will be understood that the apertures may be employed in the inking surface 36 of thecover coat drum 34 can assume any configuration suitable to dispense the thermoplastic ink within the cavity onto the siliconetransfer roller surface 38. - The rotatable silicone
transfer roller surface 38 receivesthermoplastic ink 16 from the inking surface 36 of thecover coat drum 34 and is thusly disposed in proximate contact with the inking surface 36 of thecover coat drum 34. The siliconetransfer roller surface 38 can assume the form of a drum. More specifically, it is contemplated that the siliconetransfer roller surface 38 is a sheet of sufficient flexibility to be attached to a drum core. However, thesilicone transfer surface 38 can be a drum made substantially of silicone material or materials. In any instance, the siliconetransfer roller surface 38 will preferably have characteristics to allow thetransfer roller surface 38 to collect the thermoplastic ink from the adjacently disposed inking surface 36 of thecover coat drum 34. At the same time thetransfer roller surface 38 will preferably have release characteristics that allow theink 16 to be subsequently deposited onto thesilicone transfer substrate 22. To help facilitate transfer of the ink from the siliconetransfer roller surface 38 to the subsequentsilicone transfer substrate 22, the silicone transfer roller surfaces 38 are typically and preferably maintained at temperatures in excess of the ambient temperature. - According to one embodiment, the system includes a second cover
coat print station 26. Accordingly, asecond encapsulation layer 16 may be deposited on thefirst encapsulation layer 16 to increase the overall encapsulation qualities of thelayered ink composite 14. Alternatively, the second covercoat print station 26 can be configured as a redundant print station used when the first covercoat print station 26 is non-operational. As with the first covercoat print station 26, the second covercoat print station 26 includes a rotatablecover coat drum 34 and a rotatable siliconetransfer roller surface 38 as described above. - A transfer
coat print station 30 is provided to apply second layer of thermoplastic ink 20 (i.e., the transfer layer) to thelayered ink composite 14. As shown inFIGS. 4 and 5 , the transfercoat print station 30 includes a rotatabletransfer coat drum 46 and a rotatable siliconetransfer roller surface 38. Thetransfer coat drum 46 includes a cavity for holding and dispensingthermoplastic ink 20 exhibiting the characteristics described herein. Preferably, thethermoplastic ink 20 is heated to a temperature above its melting point so that it may be inserted into thetransfer coat drum 46 in liquid form. Thetransfer coat drum 46 also includes an inking surface 36 that can be heated to a temperature in excess of the melting point of thethermoplastic ink 26. Thus, thethermoplastic ink 20 can maintain its liquid consistency such that it may be deposited in appropriate quantities onto the rotatable siliconetransfer roller surface 38. Preferably, thethermoplastic ink 18 is heated to a temperature of between 90 to 170° C. prior to the step of depositing the second layer of thermoplastic ink onto the ceramic toner. And, most preferably, thethermoplastic ink 18 is heated to a temperature of between 139 to 156° C. The inking surface 36 of thetransfer coat drum 46 can include a plurality apertures that are disposed generally in the configuration of the desired image. However, it is contemplated that inks that require heating to temperatures lower than their melting point, or which require no heating (i.e. sufficiently liquid at ambient), to maintain suitable viscosity and characteristics required for transfer and printing may be employed with the present invention. - The thermoplastic ink flowing from the
transfer coat drum 46 will be deposited onto the rotatable siliconetransfer roller surface 38 in a configuration that mirrors the desired image. However, it will be understood that the apertures in the inking surface 36 of thetransfer coat drum 46 be employed, and can assume any configuration suitable to dispense thethermoplastic ink 20 within the cavity onto the siliconetransfer roller surface 38. - The rotatable silicone
transfer roller surface 38 receives thermoplastic ink from the inking surface 36 of thetransfer coat drum 46 and is thusly disposed in proximate contact with the inking surface 36 of thetransfer coat drum 38. The siliconetransfer roller surface 38 can assume the form of a drum. More specifically, it is contemplated that the siliconetransfer roller surface 38 is a sheet of sufficient flexibility to be attached to a drum core. However, thesilicone transfer surface 38 can be a drum made substantially of silicone material or materials. In any instance, the siliconetransfer roller surface 38 will preferably have characteristics to allow thetransfer roller surface 38 to collect thethermoplastic ink 20 from the adjacently disposed inking surface 36 of thecover coat drum 34. At the same time thetransfer roller surface 38 will preferably have release characteristics that allow theink 20 to be subsequently deposited onto thesilicone transfer substrate 22. To help facilitate transfer of theink 26 from the siliconetransfer roller surface 38 to the subsequentsilicone transfer substrate 22, the silicone transfer roller surfaces 38 are typically and preferably maintained a temperatures in excess of the ambient temperature. - As discussed above, the
digital print engine 28 is disposed between the covercoat print station 26 and the transfercoat print station 30. Generally, thedigital print engine 28 of the present invention is coupled to aceramic toner supply 40 and can generate an electrostatic electrographic image fromceramic toner 18. It will be understood that theceramic toner supply 40 will includeceramic toners 18 with colored pigments that allow the system to print multi-color images. Thedigital print engine 28 of the present invention will generally include animage roller 42 and a rotatable siliconetransfer roller surface 38. According to the present invention, however, theimage roller 42 transfers the electrographically generatedtoner 18 image to the adjacenttransfer roller surface 38. However, it will be understood that digital printers capable of electrostatic or electrographic image printing using ceramic toner 18 s is known in the art. For example, thedigital print engine 28 may be of the types offered by data M Software & Engineering GmbH, Oberlaindern, Germany. - The rotatable silicone
transfer roller surface 38 of theprint engine 28 station is positioned adjacent to, and in proximate contact with, theimage roller 42. The rotatable elastomerictransfer roller surface 38 receives the generated toner image (formed from the ceramic toner 18) from theimage roller 42. The rotatable siliconetransfer roller surface 38 can again assume the form of a drum. More specifically, it is contemplated that the siliconetransfer roller surface 38 is a sheet of sufficient flexibility to be attached to a drum core. However, the silicone transfer drum can be a drum made substantially of silicone material or materials. The siliconetransfer roller surface 38 will preferably have characteristics to allow thetransfer roller surface 38 to collect theceramic toner 18 from the adjacently disposedimage roller 42. However, the siliconetransfer roller surface 38, will also preferably have release characteristics that allow theceramic toner 18 to be subsequently deposited onto thesilicone transfer substrate 22. To help facilitate transfer of the ink from the siliconetransfer roller surface 38 to the subsequentsilicone transfer substrate 22, the silicone transfer roller surfaces 38 are typically maintained a temperatures in excess of the ambient temperature. - As discussed above, the present system preferably includes a
conveyor assembly 32 suitable for transporting thesilicone transfer substrate 22 between the stations. As shown inFIGS. 4-5 , theconveyor assembly 32 generally runs below the stations such that it is positioned proximate the each of the rotatable silicone transfer roller surfaces 38. In this configuration, thesilicone transfer substrate 22 can be advanced between the transfer roller surfaces 38 of the covercoat print station 26, thedigital print engine 28 and the transfercoat print station 30. - The
workpiece 12 andsilicone transfer substrate 22, withlayered ink composite 14, can then be transported by known methods to aprinting station 44 which will include aprinting die 46. At theprint station 44 thesilicone transfer substrate 22 andlayered ink composite 14 is positioned such that the image faces theworkpiece 12. The printing die 46 can then be displaced, by known drive mechanisms, to move thesilicone transfer substrate 22, with the image formed from the layeredink composite 14, into contact with the surface of theworkpiece 12 to be imprinted with the image. The image is thereby transferred at, or near, ambient temperature from the layeredink composite 14 to the contoured surface of theworkpiece 12. - Thus, in employing the system described herein, an image can be applied to a contoured glass or ceramic dishware item. The image is transferred from a
layered ink composite 14 created by (1) depositing a first layer ofthermoplastic ink 16 onto asilicone transfer substrate 22; (2) depositingceramic toner 18 onto the first layer ofthermoplastic ink 16, the depositedceramic toner 18 configured as an electrographically generated image; (3) depositing a second layer ofthermoplastic ink 20 onto theceramic toner 18; (4) transferring the image, at or near ambient temperature, from the layeredink composite 14 to the contoured surface of the dishware item by moving either the second layer ofthermoplastic ink 20 or the contoured surface of the dishware item into contact with the other; and, (5) firing the dishware item, preferably at a temperature of about 300° to about 750° C. - While the specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the invention, and the scope of protection is only limited by the scope of the accompanying claims.
Claims (20)
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/684,564 US7887904B2 (en) | 2007-03-09 | 2007-03-09 | Method and system for printing electrostatically or electrographically generated images to contoured surfaces of ceramic and glass items such as dishware |
PCT/US2008/002857 WO2008112099A1 (en) | 2007-03-09 | 2008-03-04 | Method and system for printing electrostatically or electrographically generated images to contoured surfaces of ceramic and glass items such as dishware |
US13/022,801 US20110217088A1 (en) | 2007-03-09 | 2011-02-08 | Method and System for Printing Electrostatically or Electrographically Generated Images to Contoured Surfaces of Ceramic and Glass Items Such as Dishware |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US89405307P | 2007-03-09 | 2007-03-09 | |
US11/684,564 US7887904B2 (en) | 2007-03-09 | 2007-03-09 | Method and system for printing electrostatically or electrographically generated images to contoured surfaces of ceramic and glass items such as dishware |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US13/022,801 Division US20110217088A1 (en) | 2007-03-09 | 2011-02-08 | Method and System for Printing Electrostatically or Electrographically Generated Images to Contoured Surfaces of Ceramic and Glass Items Such as Dishware |
Publications (2)
Publication Number | Publication Date |
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US20080220188A1 true US20080220188A1 (en) | 2008-09-11 |
US7887904B2 US7887904B2 (en) | 2011-02-15 |
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Application Number | Title | Priority Date | Filing Date |
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US11/684,564 Active 2029-12-15 US7887904B2 (en) | 2007-03-09 | 2007-03-09 | Method and system for printing electrostatically or electrographically generated images to contoured surfaces of ceramic and glass items such as dishware |
US13/022,801 Abandoned US20110217088A1 (en) | 2007-03-09 | 2011-02-08 | Method and System for Printing Electrostatically or Electrographically Generated Images to Contoured Surfaces of Ceramic and Glass Items Such as Dishware |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
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US13/022,801 Abandoned US20110217088A1 (en) | 2007-03-09 | 2011-02-08 | Method and System for Printing Electrostatically or Electrographically Generated Images to Contoured Surfaces of Ceramic and Glass Items Such as Dishware |
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US (2) | US7887904B2 (en) |
Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
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CN108297468A (en) * | 2017-12-27 | 2018-07-20 | 惠州Tcl移动通信有限公司 | A kind of processing method, shell and the mobile terminal of ceramics appearance tactile impression shell |
EP3391153A4 (en) * | 2015-12-16 | 2019-11-27 | Eng Kah Enterprise Sdn Bhd | Laser printed photo on glass article method thereof |
CN111391495A (en) * | 2020-05-09 | 2020-07-10 | 江苏美思奇智能科技有限公司 | Integrated form bat printing, storage device |
US10759973B2 (en) | 2015-10-15 | 2020-09-01 | Tesa Se | Adhesive mass, in particular for strippable adhesive strips and use for adhering on coated woodchip wallpaper |
CN112172329A (en) * | 2020-10-21 | 2021-01-05 | 泉州尚德服饰有限公司 | Multicolor ink pad printing or heat transfer printing machine |
GB2617084A (en) * | 2022-03-28 | 2023-10-04 | Ball Kevin | Printing method |
US20230418202A1 (en) * | 2022-06-28 | 2023-12-28 | Fujifilm Business Innovation Corp. | Image forming apparatus |
US12078949B2 (en) * | 2022-06-28 | 2024-09-03 | Fujifilm Business Innovation Corp. | Image forming apparatus |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
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CN106626748B (en) * | 2017-01-24 | 2019-01-18 | 沙伯特(中山)有限公司 | A kind of full-automatic disc thermoprinting machine |
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US4472537A (en) * | 1982-09-17 | 1984-09-18 | Corning Glass Works | Thermoplastic inks for decorating purposes |
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US4035214A (en) * | 1975-07-21 | 1977-07-12 | American Can Company | Total image transfer process |
JPH07300382A (en) | 1994-05-09 | 1995-11-14 | Narumi China Corp | Image-printed ceramic and method for producing the same |
JPH0811496A (en) | 1994-07-01 | 1996-01-16 | Brother Ind Ltd | Toner for decoration on ceramic, transfer sheet, and decorating method for ceramic product |
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- 2007-03-09 US US11/684,564 patent/US7887904B2/en active Active
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US4542052A (en) * | 1982-05-18 | 1985-09-17 | Esselte Pendaflex Corporation | Transfer imaging systems |
US4472537A (en) * | 1982-09-17 | 1984-09-18 | Corning Glass Works | Thermoplastic inks for decorating purposes |
US5204164A (en) * | 1990-03-02 | 1993-04-20 | Brother Kogyo Kabushiki Kaisha | Image transferred material |
US6745684B1 (en) * | 1999-08-13 | 2004-06-08 | Schott Glas | Printing device or printing method |
Cited By (9)
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US10759973B2 (en) | 2015-10-15 | 2020-09-01 | Tesa Se | Adhesive mass, in particular for strippable adhesive strips and use for adhering on coated woodchip wallpaper |
EP3391153A4 (en) * | 2015-12-16 | 2019-11-27 | Eng Kah Enterprise Sdn Bhd | Laser printed photo on glass article method thereof |
JP2019214510A (en) * | 2015-12-16 | 2019-12-19 | イーエヌジー カ エンタープライズ スンディリアン ブルハドEng Kah Enterprise Sdn. Bhd. | Method for laser printing image on glass product |
CN108297468A (en) * | 2017-12-27 | 2018-07-20 | 惠州Tcl移动通信有限公司 | A kind of processing method, shell and the mobile terminal of ceramics appearance tactile impression shell |
CN111391495A (en) * | 2020-05-09 | 2020-07-10 | 江苏美思奇智能科技有限公司 | Integrated form bat printing, storage device |
CN112172329A (en) * | 2020-10-21 | 2021-01-05 | 泉州尚德服饰有限公司 | Multicolor ink pad printing or heat transfer printing machine |
GB2617084A (en) * | 2022-03-28 | 2023-10-04 | Ball Kevin | Printing method |
US20230418202A1 (en) * | 2022-06-28 | 2023-12-28 | Fujifilm Business Innovation Corp. | Image forming apparatus |
US12078949B2 (en) * | 2022-06-28 | 2024-09-03 | Fujifilm Business Innovation Corp. | Image forming apparatus |
Also Published As
Publication number | Publication date |
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US7887904B2 (en) | 2011-02-15 |
US20110217088A1 (en) | 2011-09-08 |
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